Ultrasonic Industrial Defectoscope
Research and Development of the Ultrasonic Instrument for Industrial Quality Control and Quality Assurance for the Ecological Safety of Industrial Organizations
Tech Area / Field
- INF-SIG/Sensors and Signal Processing/Information and Communications
- INS-DET/Detection Devices/Instrumentation
8 Project completed
Senior Project Manager
Kulikov G G
Oktyabr Production Association State Enterprise, Russia, Sverdlovsk reg., Kamensk-Uralsky
- Central Research and Development Institute of Metallurgy and Metals, Russia, Sverdlovsk reg., Ekaterinburg
Project summaryThe considerable amount of industrial institutions, using the modern technology achievements, is surely complex technological structures. They carry the potential danger for the personnel, environment and ecological situation in total. As a rule, the safe running of industrial institutions in a great measure depends on the correct usage of non-destructive control, allowing evaluating the level of faults in machinery as well as the level of action of corrosive atmosphere, high pressure and temperature on metals longevity. Two methods are being used for internal fault detection: radiographic and ultrasonic one.
The radiographic method employs ionizing radiation, thus creating difficulties in providing a biological shielding for the personnel and environmental control. In this connection the ultrasonic control method is widely used. It's based on the feature of ultrasonic fields to penetrate through a solid and reflect from metal' defects such as cracks, pores, cavities, slag blowholes. At the present day, the Russian industry employs analogue one-channel ultrasonic devices. Devices do not have microprocessors, so they can't provide complex processing of received signals thus reliability of the control results isn't high enough, as it is required by equipment safety specifications.
In recent years, many countries conduct intensive researches in the possibility to use modern computer technologies for improvement of reliability of the ultrasonic control results. "KRAUTKAMER" company (Germany) produces ultrasonic defectoscopes based on portable computer. Those defectoscopes are expensive, difficult to use ones and require qualified personnel.
The technical purpose of the current project – researches on estimating the optimal parameters for ultrasonic defectoscopes depending on the running conditions; investigations on a possibility of the optimal use of modern computer technology allowing to increase the reliability of control results as well as improvement in revealing defects of the metal, thus increasing safety of use the equipment dangerous for environment.
It is projected to conduct researches and create the line of ultrasonic defectoscopes, consisting of three models as follows:
Model 1. Portable microprocessor handheld one-channel defectoscope for field usage.
Model 2. Portable microprocessor handheld one-channel defectoscope with a PC RB 2000 Navigator for running in a workshop area.
Model 3. Microprocessor four-channel ultrasonic defectoscope with a PC HP Vectra VE17 DT C500 PII 500 MHz for running in an automatic control systems.
The participating institution Production association "OKTYABR" State Enterprise has at its disposal:
Personnel that are high qualified in the field of producing homing (guidance) systems devices and control equipment for missile weaponry (appropriate code number of ISTC in missile technology is 1.2). In the current time, they do not make the maximal use of the professional skills of the personnel. Some of the weaponeers were offered the employment in the countries having an astable regime. Those weaponeers possess the technology of R&D of complex devices utilizing a microprocessor technology.
The participating institution Central Research and Development Institute of metallurgy and metals has conducted the R&D and predictive schemes as well as analytical investigations concerning the ultrasonic defectoscopy issue. It has at its disposal competent authorities and experts that are able to conduct a task-oriented research and to employ its results for devising a RFP (request for proposal) for the line of industrial defectoscopes.
The project proposed meets the purposes as follows:
1. Provides the concrete field for moving the knowledge and experience of experts engaged in producing homing (guidance) systems for missile weaponry, toward peaceful activity.
2. Supports applied researches concerning the problem of designing the effective devices for non-destructive control, existing both in Russia and abroad.
3. Supports weapons experts in accommodation and finding their niches in a market economy being developed in Russia.
4. Integrating hi-qualified weapons experts into the international science community by collective activity in designing topical devices for non-destructive control.
5. Handles the crucial problem of Russia in designing of a modern ultrasonic defectoscope complying the world level of design and having a lower price.
The amount of research efforts is tentatively allocated as follows:
1. Research and development, carrying out the tests - Central Research and Development Institute of metallurgy and metals (25%).
2. Participation in research and development, prototypes manufacturing, carrying out the tests - Production association "OKTYABR" State Enterprise (75%).
Foreign collaborators FRAUNHOFER institute (JZFP) and SIEMENS Non-Destructive Testing Gmbh & Co KG participate in research and design of electronic circuits of prototypes, laying special emphasis on physical principles of non-destructive control, sensors and instruments for different industrial applications. The following range of collaboration is expected:
- Collaborative and parallel investigations and researches prosecution.
- Holding joint workshops, symposiums, conferences and consultations.
- Results supervision using independent methods.
- Collaborative investigation of reports.
- Consultations concerning the right of intellectual property in case of joint invention.
When performing researches, modern methods of design and computer processing of test results will be applied.
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